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IBM 6500-V5P Maintenance Manual - Page 198

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General Symptom List Table 5. General Symptom List Symptom Corrective Action Vertical misalignment of characters: 1. Dots or characters move up or down from dot row to dot row or line to line 2. Incorrect spacing from dot row to dot row or line to line 3. Characters randomly compressed and/or enlarged 1. Load paper. Press FORM FEED and check that paper feeds smoothly. Press VIEW to verify that paper moves in both directions. Check the forms thickness lever: if it is set too loose or too tightly print quality can be affected. Set the forms thickness lever to match the thickness of the paper being used. 2. Check and adjust the paper feed timing belt. Replace the belt if it is damaged. 3. Check and adjust the platen gap. 4. Check and adjust the dynamic paper tension (page 384). 5. Check and adjust the tractor belt tension (page 387). 6. Check for heavily tented horizontal perforations in the paper. If horizontal perforations are heavily tented, consider setting the "Set Platen at BOF" configuration option (in the Printer Control menu) to Open. (Refer to the User's Manual.) 7. Inspect the tractors and tractor door springs for damage, excessive wear, and equal door closing tension. If either tractor is worn, damaged, or exhibits uneven door closing tension, replace both tractor assemblies. 8. Remove the paper guide assembly or pedestal top cover. Make sure connector P107/PAPR M is fully seated in connector J107 on the controller board. 9. Power on the printer. Load paper. Run a print test. If the problem occurs, replace the paper feed motor. 10. Check the shuttle for electrical shorts (page 252). 11. Power on the printer. Run a print test. If the problem occurs, the controller board or microcode is suspect. Do the following: 12. Save the printer configuration values. (Refer to the User's Manual.) 13. Clear NVRAM (page 237). 14. Download and install the latest code from IBM First (page 231). 15. Power on the printer in download mode and load flash memory (page 238). a. If you encounter loading problems, go to the appropriate error code for resolution. b. If you encounter the failure or message that brought you to this procedure, replace the controller board (page 319). After replacing the controller board, DO NOT make the printer READY, but proceed immediately to the next step. 198

Section	Page
ENERGY STAR	10
Notices	10
Communication Statements	12
Federal Communications Commission (FCC) Statement	12
European Union (EU) Conformity Statement	12
Industry Canada Compliance Statement	13
Statement of CISPR 22 Edition 2 Compliance	13
Japanese VCCI Class A	13
Japanese JEITA Statement	14
Taiwan	14
Australia/New Zealand	14
Korea	15
China	15
German Conformity Statement	15
European Union (EC) Electromagnetic Compatibility Directives	16
Electrical Safety	17
Lightning Safety	17
Safety And Notices	17
Trademarks and Service Marks	19
Safety Inspection	21
Preparation	21
Prepare The Printer For Inspection	21
Inspect Mechanical Parts	22
Top Cover And Cabinet Doors	22
Print Mechanism	22
Inspect Electrical Parts	23
Safety Ground Path	23
Customer Power Source Service Check	25
Power Cable	25
Power On / Off Verification	25
Print Interlock Service Check	26
Preface	26
About This Manual	26
How To Replace Parts	26
How To Order Parts	27
Printing Conventions In This Manual	27
Related Documents	28
About The Printer	29
The IBM Infoprint 6500 Printer Family	29
How To Identify The Printer	30
Printer Configuration Code	31
Forms Handling	32
Important Maintenance Notes	33
Controls And Indicators	34
Electrical Controls: Figure 5	34
Mechanical Controls: Figure 6	37
1 Diagnosing Problems	39
Introduction	39
Troubleshooting At A Glance ...	39
Start Of Call	40
How To Troubleshoot	41
Troubleshooting Display Messages	42
Display Messages	42
Troubleshooting Other Symptoms	170
Communication Problems	171
Device Handshaking	174
The Printer Interface	174
General Symptom List	176
2 Diagnostics	212
Contents	212
Operator Print Tests	213
Selecting And Running Tests	215
Customer Engineer (CE) Tests	216
Selecting And Running CE Tests	220
Boot Diagnostics Menu	221
Activating The Boot Diagnostics Menu	221
Exiting The Boot Diagnostics Menu	221
Hex Code Printout	224
Printer Information Menu	226
Displaying Printer Information	227
Soft vs. Hard Reset	228
Soft Reset	228
Hard Reset (“Cycle Power”)	228
Controller Board Status LEDs At Power Up	229
Troubleshooting A New Installation	230
Printer Configuration	230
Documentation	230
RibbonMinder**	231
RibbonMinder Operation	231
Operator Panel Menus	231
Ribbon End Point	232
Ribbon Action	233
Ribbon Installation And Detection	234
The Ribbon Log	235
Downloading Microcode From IBM First	236
Clear NVRAM	237
Loading Flash Memory	238
Loading Through The Serial Or Parallel Port	239
Loading Through the Network Interface Card (NIC)	248
Reprogramming the Security Key	250
How To Reprogram The Security Key	250
Shuttle Electrical Shorts Test	252
Hammer Bank Power Cable Shorts Test	253
Cable Shorts Test	254
The Procedure:	254
Main Wire Harness Test Diagnostic	256
Power Supply Operational Check	258
3 Locations	262
Locations Of Components And Assemblies	262
4 Circuit Diagrams, Circuit Boards, Cables, and Switches	264
Contents	264
Interconnection Diagram	266
Power Distribution Diagram	267
Main Wire Harness Test Tables, PSA3 Controller Board	268
PSA3 Controller	269
Power Supply: 6500-v05, -v5P, -v10, and -v1P	277
Power Supply: 6500-v15	278
Power Supply: 6500-v20	279
IBM Coax/Twinax Expansion Board for PSA3 Controllers	280
SureStak Power Stacker PCBA	281
Cable Routing, Cabinet Model	282
Cable Routing, Pedestal Model	283
Cable Assembly, Centronics I/O	284
Cable Assembly, Centronics/Dataproducts Adapter	285
Cable Assembly, +5V Remote Power	286
Cable Assembly, Twinax Auto-Termination	287
Cable Extension, Smart-T	288
Cable Assembly, PS I/O, 2000	289
Cable Assembly, AC In, Power Supply	290
Cable Assembly, AC Power Input	291
Cable Assembly, Card Cage Fan	292
Cable Assembly, Operator Panel	293
Cable Assembly, Exhaust Fan	294
Cable Assembly, Hammer Bank Logic	295
Cable Assembly, Hammer Bank Power	296
Cable Assembly, Hammer Bank Power	297
Cable Assembly, MPU	298
Cable Assembly, Ribbon Guide	299
Cable Assembly, Ribbon Motor, Extension	300
Cable Assembly, Shuttle Motor Drive	301
Frame Cable, Power Stacker	302
Logic Cable, Power Stacker	303
Power Cable, Power Stacker	304
Vertical Rail Cable, Power Stacker	305
Elevator I/O Cable, Power Stacker	306
Fan Assembly, Hammer Bank	307
Magnetic Pickup (MPU) Assembly	308
Switch Assembly, Paper Detector	309
Switch Assembly, Platen Interlock	310
5 Removals and Adjustments	311
About This Chapter	311
Tools And Materials	311
Preparing The Printer For Maintenance	313
Restoring The Printer To Operation	314
Removal And Replacement Procedures	315
List Of Procedures	315
Belt, Paper Feed Timing	317
Removal	317
Installation	317
Belt, Platen Open	318
Removal	318
Installation	318
Circuit Board: PSA3 Controller	319
Removal	319
Installation	320
Circuit Board: Power Supply	321
Removal	321
Installation	321
Circuit Breaker	322
Removal	322
Installation	322
Connector Shells	323
Removal	323
Installation	323
Cover Assembly, Hammer Bank / Ribbon Mask	325
Removal	325
Installation	325
Cover Assembly, Shuttle	326
Removal	326
Installation	326
Cover Assembly, Top, Pedestal Model	327
Removal	327
Installation	327
Dashpot	328
Removal	328
Installation	328
Ethernet Interface Assembly	329
Removal	329
Installation	329
Fan Assembly, Cabinet Exhaust	330
Removal	330
Installation	330
Fan Assembly, Card Cage	331
Removal	331
Installation	331
Fan Assembly, Hammer Bank	332
Removal	332
Installation	332
Hammer Spring Assembly	333
Removal	333
Installation	335
IBM Coax/Twinax Expansion Board	337
Removal	337
Installation	337
Magnetic Pick-up (MPU) Assembly	338
Removal	338
Installation	338
Memory Modules and Security Key	339
Removal	339
Installation	340
Motor Assembly, Paper Feed	342
Removal	342
Installation	343
Motor Assembly, Platen Open	344
Removal	344
Installation	345
Motor Assembly, Ribbon Drive	346
Removal	346
Installation	346
Operator Panel Assembly	347
Removal	347
Installation	347
Paper Guide Assembly	348
Removal	348
Installation	348
Paper Ironer	349
Removal	349
Installation	349
Platen	350
Removal	350
Installation	351
Platen Stop Assembly	354
Removal	354
Installation	354
Resistors, Terminating	355
Removal	355
Installation	355
Ribbon Guide Assembly (L/R)	357
Removal	357
Installation	357
RibbonMinder** Sensor	358
Removal	358
Installation	358
Shaft, Splined	359
Removal	359
Installation	359
Shaft, Support	361
Removal	361
Installation	361
Shuttle Frame Assembly	362
Removal	362
Installation	363
Spring, Extension, Hammer Bank	364
Removal	364
Installation	364
Switch Assembly, Paper Detector	365
Removal	365
Installation	365
Switch Assembly, Platen Interlock	366
Removal	366
Installation	366
Tractor (L/R)	367
Removal	367
Installation	367
Adjustment Procedures	368
List Of Adjustments	368
Belt, Paper Feed Timing, Adjustment (Figure24)	369
Belt, Platen Open, Adjustment (Figure25)	371
Paper Scale Alignment (Figure26)	373
Platen Gap Adjustment (Figure27)	374
Ribbon Guide Alignment (Figure28)	376
Adjusting The End Of Forms Distance	378
Hammer Phasing Adjustment	381
Coil Temperature Adjustment	383
Dynamic Paper Tension Adjustment	384
Tractor Belt Tension Adjustment	387
Ethernet Initialization	389
6 Parts Catalog	390
Organization Of This Chapter	390
Illustrated Parts Breakdown	390
7 Preventive Maintenance	431
Contents	431
Cleaning The Printer	432
Cleaning The Exterior	432
Cleaning The Interior	433
Cleaning The Shuttle Frame Assembly	434
Cleaning The Card Cage Fan Assembly	436
A Installing And Relocating The Printer	437
Installing And Configuring The Infoprint 6500 Printer	437
Relocating The Infoprint 6500 Printer	437
B Communication Adapters	438
Contents	438
Ethernet Interface Assembly	439
Ethernet Troubleshooting Tips	439
Tip 1: Infoprint 6500 IPDS Communication Failure	439
Tip 2: Ethernet Port Not Enabled, PMU Not Communicating	440
Tip 3: Connecting Laptop to Printer via Ethernet Port for Diagnosing Communication Problems	441
Tip 4: Telnet to the Printer	442
Tip 5: Printer Does Not Communicate	442
IBM Coax/Twinax Expansion Board	444
C Power Cords And Adapters	445
D ASCII Codes	447
E SureStak** Power Stacker	451
Contents	451
Introduction	452
How To Operate The Power Stacker	453
Stacker Operator Panel	454
Using The Power Stacker	455
Loading and Starting the Power Stacker	457
Stacker Problems	459
Removing The Power Stacker	465
Installing The Power Stacker	473
Replacing The Constant Force Spring	485
Replacing The Timing Belts	487
Replacing The Roller Drive Shaft	491
Illustrated Parts Breakdown	494
List of Illustrations	494
F Printer Specifications	504
Contents	504
Ribbon Specifications	505
Ordering Ribbons	505
6500-v Models	505
United States and Canada	505
EMEA	506
AP and LA	506
Warranty Information	506
Paper Specifications	507
Labels	508
Printer Dimensions and Weight	508
Cabinet Models	508
Pedestal Models	508
Environmental Characteristics	509
Temperature	509
Relative Humidity	509
Noise Levels	509
Electrical Characteristics	510
Interfaces	511
Cables	511
Printing Rates	512
G Metric Conversion Tables	515
Length	515
Torque and Force	516
Mass and Density	516
Temperature	517
Power	517
H Torque Table	518
I Abbreviations	520
Numerics	532
A	534
B	534
C	534
D	535
E	536
F	536
G	537
H	537
I	537
K	538
L	538
M	538
N	538
O	538
P	539
R	540
S	541
T	542
U	543
W	543

Match case Limit results 1 per page

General Symptom List

198

Vertical misalignment of characters:

1. Dots or characters move up or

down from dot row to dot row or line to

line

2. Incorrect spacing from dot row to

dot row or line to line

3. Characters randomly compressed

and/or enlarged

Load paper. Press

FORM FEED

and check that paper feeds smoothly. Press

VIEW

to verify that

paper moves in both directions. Check the forms thickness lever: if it is set too loose or too tightly

print quality can be affected. Set the forms thickness lever to match the thickness of the paper being

used.

Check and adjust the paper feed timing belt. Replace the belt if it is damaged.

Check and adjust the platen gap.

Check and adjust the dynamic paper tension (page 384).

Check and adjust the tractor belt tension (page 387).

Check for heavily tented horizontal perforations in the paper. If horizontal perforations are heavily

tented, consider setting the “Set Platen at BOF” configuration option (in the Printer Control menu) to

Open. (Refer to the

User’s Manual

Inspect the tractors and tractor door springs for damage, excessive wear, and equal door closing

tension. If either tractor is worn, damaged, or exhibits uneven door closing tension, replace both

tractor assemblies.

Remove the paper guide assembly or pedestal top cover. Make sure connector P107/PAPR M is

fully seated in connector J107 on the controller board.

Power on the printer. Load paper. Run a print test. If the problem occurs, replace the paper feed

motor.

10.

Check the shuttle for electrical shorts (page 252).

11.

Power on the printer. Run a print test. If the problem occurs, the controller board or microcode is

suspect. Do the following:

12.

Save the printer configuration values. (Refer to the

User’s Manual

13.

Clear NVRAM (page 237).

14.

Download and install the latest code from IBM First (page 231).

15.

Power on the printer in download mode and load flash memory (page 238).

If you encounter loading problems, go to the appropriate error code for resolution.

If you encounter the failure or message that brought you to this procedure, replace the controller

board (page 319). After replacing the controller board, DO NOT make the printer READY, but

proceed immediately to the next step.

Table 5. General Symptom List

Symptom

Corrective Action